Precision assembly technique using alignment fixture and the resulting assembly

Abstract

According to a precision assembly technique, a first subassembly is precisely aligned relative to a plurality of alignment features in an alignment fixture and at least three non-coplanar flexures having complementary alignment features are located with respect to corresponding alignment features on the alignment fixture and mechanically attached to the first subassembly. The first subassembly with the attached flexure sheets is removed from the alignment fixture and located with respect to a second subassembly having a plurality of alignment features identical to the alignment features in the alignment fixture using the alignment features on the second subassembly and the complementary alignment features on the flexure sheets to precisely align the first subassembly with the complementary alignment features on the second subassembly. The flexure sheets are then mechanically attached to the second subassembly, whereby the first and second subassemblies are aligned and rigidly connected to one another.

What is claimed is: 
     
       1. A laser scanner, comprising: a) a scan optics module;   b) a scanner body having a recording drum, the scanner body defining a plurality of alignment features; and   c) a flexure coupling for aligning and rigidly connecting the scan optics module to the scanner body, the flexure coupling including three noncoplanar sheet flexures each defining an alignment feature for cooperating with a corresponding alignment feature on the scanner body for aligning the scan optics with the scanner body and rigidly supporting the scan optics module with respect to the scanner body, each sheet flexure defining a plurality of oversize holes for securing the flexure to the scanner body with screws after alignment of the scan optics module with the scanner body.   
     
     
       2. The laser scanner claimed in claim 5, wherein the recording drum has a rotational axis; the alignment features on the scanner body include a pair of spaced apart circularly cylindrical surfaces co-axial with the rotational axis of the recording drum; and the corresponding alignment features on two of the sheet flexures are v-shaped features adapted to cooperate with the circularly cylindrical surfaces. 
     
     
       3. The laser scanner claimed in claim 2, wherein the alignment features on the scanner body include a hole for receiving a bolt, and the corresponding alignment feature on the third sheet flexure is an elongated hole having an edge that is adapted to engage a bolt in the hole in the scanner body.